Root Cause Analysis is a tried and tested method of identifying, analyzing and solving problems. There are many unique tools and methods available. This can be a challenge. What tool will work in your company? Which method is suited to your business environment? Are your current tools effective?

• The aim of this course is to provide supervisors and managers exposure to different options to consider.
• A list of the top 20 RCA tools available.
• Hard copy templates that are filled in each day.
• A sample Power Point presentation template.
• A3 report and 8D report template to choose.
• Depending on the tool selected; the delegate can prepare his/her practical exercises which can be presented to management if required.
• Delegates are introduced to maintenance, production; quality and supply chain analysis opportunities via the facilitator and team members. Group work and case studies are done.
• All tools are simplified and user friendly.

The course can be done manual or soft copy.

Day 1

Understanding the 5 types of RCA:

Each type is explained, using examples as a group work activity.

1. Health & Safety:

• Incident/accident report.
• Risk Matrix.

2. Production:

• Kaizen – waste identification
• Lean manufacturing – resource utilization

3. Quality:

• The 7 tools of quality

4. Maintenance & Engineering:

• FTA
• FMEA

5. Supply Chain Management:

• Supplier evaluation
• Value engineering

Understanding the human analysis tools available:

• Psychometric tools: Industrial psychology.
• Why do people make mistakes?
• What is motivation? How to motivate.
• Solutions to human errors with examples.

Day 2

RCA tools and short exercises:

1. Mind mapping: Group creativity techniques.
2. TRIZ: A Russian method with a design focus
3. Kepner & Tregoe: IS/IS NOT Analysis
4. Flowcharts
5. Change analysis
6. Barrier analysis
7. OCCAMS Razor
8. Failure Mode Effects Analysis (FMEA)
9. Fault Tree and Logic Gates
10. Scientific experiments
11. Destructive testing
12. Simulations
13. Pictograms
14. What Would X do?
15. Poka Yoke
16. Condition Based Maintenance
17. Condition Monitoring tools
18. Incident/Accident report (WORD template)
19. Clinical trials and scientific experiments
20. FRACAS: Reporting template for consideration

Day 3

Selecting suitable tools

• Match the top 20 tools to business environment.
• Select a combination of tools that could work.
• Do a practice run hard or soft copy as preferred.

Implementing the correct tool to use:

• 5W2H hard copy
• SMART hard copy
• Excel tools:
• Check sheet
• Pareto
• Fishbone
• Scatter diagram
• Histogram
• Graphs
• Control chart
• Investigator Progress Chart (Spider Graph)
• Other implementation tools:
• Corrective Action Report
• A3 report
• 8D report
• Redesign on “bad actors”. RCM methods.
• IS/IS NOT report
• RCA Lead Investigator Checklist
• RCA Lead Investigator Report Form (Summarized)
• FRACAS (Short sample only)
• Project Management methods

Preparing for the RCA & Motivations

• Select the RCA team members.
• Select the lead auditor and facilitator.
• Set up the interview facility.
• Use many investigation methods.
• Write a detailed report and submit evidence.
• Write and implement the solution(s).

The following are example type of problems that the delegate can choose to analyze:

• Engineering: Design errors; equipment lifespan.
• Maintenance: Machine reliability. Failures
• Production: Waste elimination. Reworks.
• Quality: Reduce customer returns.
• Logistics: Reduce supply or storage problems.
• HR: Staff training & motivation.
• Civils: Leaks, cracks; drainage; plant extensions.
• Kaizen: Improvement of “bad actors” areas.
• TPM: Work cell area 5S implementation.
• Any specific problem areas assigned by management to the delegate and the facilitator.

Available on request.

This course is suited to novice and experienced managers.

• The novice is introduced to the many tools and methods available. He/she can learn the best options going forward. It is better to make informed decisions.
• The experienced manager revises his/her current tools and methods and judges their effectiveness. It is good to compare current methods and look for upgrades.

This has huge benefits for both the employee and plant performance. Using the right tools and methods ensures that the RCA is done right the 1^st time.